Three-layer Cross-linked Cable Extrusion Line

3-layer cable extrusion is a manufacturing process where three layers of material are applied to a cable's conductor simultaneously through a single die, often used for high-performance cables. This technique applies layers like the conductor screen, insulation, and insulation screen at once, creating a more durable, high-quality product with superior protection against moisture and physical damage.

How it works

Simultaneous extrusion: Three separate extruders feed material into a specialized triple-layer crosshead, which directs the materials to form a single, integrated structure around the conductor.

Layer composition: The three layers typically consist of:

Conductor screen: A semiconductor layer directly over the conductor.

Insulation: The main dielectric insulation layer, often made of cross-linked polyethylene (XLPE).

Insulation screen: A final semiconductor layer that acts as a shield.

Co-extrusion die: The materials flow through a single die, ensuring perfect contact between the layers and preventing any gaps or contamination.

Cross-linking: After extrusion, the cable's insulation and screens are chemically cross-linked in a controlled environment (like a nitrogen atmosphere) to enhance their physical properties.

Quality control: The thickness and concentricity of each layer are continuously monitored by an X-ray measuring head to ensure they meet specifications.

Benefits of 3-layer extrusion:

Enhanced durability: Creates a thicker and more robust insulation system.

Superior quality: Eliminates the possibility of moisture or dust particles entering the layers during manufacturing.

High performance: Produces high-tolerance, high-performance cables suitable for demanding applications, particularly medium and high-voltage power cables.

Efficiency: The process is continuous and highly efficient, producing high quantities of cable with minimal waste.

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